Flashing OD & 4x4 lights, strange noises... more!

[bigrnu]

(I've searched extensively, and found no real good answers, or "where to go next" posts)

1997 Explorer Sport, 4.0 SOHC, AWD, automatic. 106,000 miles. Real mess of troubles.

Problem 1....
While driving around town, at completely random times, my 4x4 HI and 4x4 LOW lights will start flashing. Usually the standard six flashes, take a minute or two brake, followed by six more flashes. When the lights flash, I am unable to lock into 4 HIGH. Cycling the ignition key (off/on) resets the status, and allows 4 HIGH to function normally.

My local mechanic pulled codes, and told me I needed a new 4x4 shift motor. Does this sound correct?

Problem 2...
At low speeds (parking lots, etc), 4x4 switch in AUTO position, and while turning left or right, resistance is felt in (presumably) the front end. It is accompanied by a whining/groaning noise, and usually stops after a loud clunk/bang. Sometimes only does it initially after starting the vehicle... But recently, has started doing it more often (like when stopped at a stop sign, and then turning sharp). The only thing I have done recently was remove the rear speed sensor (on the transfer case), and cleaned it off. I noticed what could have possibly been a crack on the face of the sensor.

Problem 3...
At interstate highway speeds (above 70 MPH), the Overdrive OFF light starts flashing, and engine RPMs stay higher than normal. The tranny immediately goes into limp mode, and fuel economy decreases fairly dramatically (presumably due to engine RPMs). The only way to get the light to stop flashing is to let the vehicle sit overnight, or disconnect the battery. But - it starts flashing again every time I take the vehicle above 70 MPH. At 60-65 MPH, I can drive all day long and not get a single light to flash.

Local mechanic pulled codes - said it was a torque converter code (but neglected to tell me the actual code). Said tranny needs to be replaced. I disagree... After reading many threads here.

Where I am thinking of starting: I'd like to replace the 4x4 shift motor with a rebuilt unit, and replace both speed sensors on the transfer case. Also would like to get tranny and transfer case flush accomplished, as I have not done this yet since I bought it (89,000 miles then, 106,000 miles now).

I DO hate purchasing parts with the mentality of "replace stuff till it's fixed", so I would appreciate any advice. It seems I have two unrelated problems, but I'm not sure where to start.

How about the torque converter solenoid? Another possible culprit? Where is this solenoid located, anyway?

Thanks in advance for any advice.

 

[Sterling]

Problem 2 sounds like the power steering fluid is low. fill up the fluid till it just overflows onto the engine start it up and full turn it both ways over and over. If after 15 times of this and it keeps up with full fluid, it's a much deeper problem.

I get the same problem only because I loose a 1/2cup of fluid a day.

 

[dreamr]

There are several things in the second gen control trac system that could cause the flashing 4x4 lights. However as you described it it sounds like your vehicle is stuck in 4 high. A tranny shop has the computer tool to spike it back into auto.. However you will likely end up at the dealership.....

It is not a frequent concern, but also far from unheard of for the system to get stuck in 4 hi. The dealership can usually reflash your GEM module, but occasionally it will need a new GEM unit. Mine was $260 when it went out.

The sensor you mentioned.... was it the one on the rear dif, or one of the two in your t-case. Either way they are hall effect sensors in function. The rear is for the ABS system and the t-case pair send info for the auto feature. If they are cracked, replace it as it may be the cause of your issue.

One more edit
Don't replace the shift motor. It is likely not the cause of this issue, though it could be....do a search for the shift motor rebuild thread. 5 bucks to repair if even that vs. over a hundred for a new one.

 

[BrooklynBay]

Welcome to this forum! The first thing to do before tearing your vehicle apart like swiss cheese is to have the codes read. You could go to AutoZone to have them read for free. Don't replace any parts without first posting the codes here. There is a sticky written by ExplorerDMB in the under the hood section that has links for EEC V codes. You have an OBD II system. The solenoids are located inside of the transmission on the bottom where the valve body is located.

 

[dreamr]

Autozone will not be able to pull these codes unless they are quite a fancy store with machine worth several thousand dollars. A standard code reader will only access the codes stored in the ECU. The Gem module is a seperate computer that runs many of your accessories including 4x4. There is special software for reading these codes through the standard OBDII port, but it is not a machine that will be available at AutoZone. You will have to go to a tranny shop used to dealing with fords or go to ford.

In short clean your hall effect sensors and replace if broken.
Still got a problem try the shift motor rebuild.
Still a problem I suggest the diagnostics recommended earlier in this post as stuff starts to get expensive quick. Some tranny shops will pull your codes for free or cheap, but the dealership will charge their diagnostics fee.

It took them 14 hours to figure out that mine was the GEM even though I told them when I walked in as I had tested the entire system already and knew damn well where the problem was.

 

[dreamr]

Oh yeah.... I know very little about the transmission, so I will wait for Glacier to chime in

Strikes me though that if you need codes read and have tranny concerns it might be wise to find a Transmission shop in the area soon

 

[BrooklynBay]

Glacier also loans tools with a deposit if you need a code reader, or a scanner.

 

[dreamr]

I think that the scanner needed here would not fall into the loan program too easy

Unless Glacier is even nicer of a guy than I thought.

Perhaps he or some of our other techs can jump in and explain about Ford's fun little scan tool they use for this. I am not talking about an OBD II scanner you can by at the local auto parts store.

 

[hardazz06]

hey ive had many of the same problems on my 97 awd!!! First off that clunk you hear is your transfer case in 4lo or hi + your cv axels popin due to sharp turns in parking lots...

The reason for this is your shift motor or any electrical feeding up to it.. your shift motor is changing the range of you shift fork within your t-case but when the shift motor isnt fully operable it gets stuck in between drivetrain gears not allowing the shift fork to fully actuate in or out of 4wd.. now the result of this is your dash will be lit up with 4x4 lights plus some very wierd electrical problems... the reason for these problems is your GEM( electrical brain for your 4x4 control trac)... This modulator doesnt know whats going on with your t-case because its stuck between gears and lets just say is off a page...

What you need to do is take it to a electrical shop and have them pull up all the wiring shkematics from you 4x4 switch to your speed sensors plus your GEM... Ive been in your situation for years now .. and fixing mechanical parts has not worked... YOU HAVE ELECTRICAL PROBLEMS +plus some mechanical problems because of your faulty electrical.... Now electrical work is real exspensive from 50$ hr to 100 $hr... I know this isnt worded too well but im in a hurry and this artical caught my eye... I can tell you the first part to go out is your CV axels and from there it gets much worse